What is Industry 4.0 and how is it shaping the future of the mining industry

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Put simply, Industry 4.0 or Mining 4.0, refers to the fourth industrial revolution due to the progress of internet and satellite navigation. There are those that dismiss Industry 4.0 as a marketing buzzword, however we believe it is a helpful phrase to explain the shift from the past three revolutions of mechanisation, electrification, and information technologies.

As digital technology such as automation, sensors, cameras, touchscreens, and artificial learning become more prevalent there is increased pressure on mining companies to leverage it for extra gains. The value of Industry 4.0 comes from finding digital ways to control physical assets like drills, trucks, and other machinery, to make operations safer, more productive, and more sustainable.

Let us explore Industry 4.0 in more detail and how it will shape the mines of the future.

Industry 4.0

Industry 4.0 follows the transitions of:

The industrial resolution of mechanisation through water and steam power
Mass production and assembly lines using electricity
The adoption of computer and automation.

The fourth revolution – Industry 4.0 – will enhance what was started in the third revolution. The adoption of computers and automation will be enhanced with smart and autonomous systems fuelled by data and machine learning. Industry 4.0 continues to unfold however it involves computers being connected and “talking” to each other, to make decisions without human involvement.

As Forbes Magazine explains Industry 4.0 in the manufacturing industry:

“A combination of cyber-physical systems, the Internet of Things and the Internet of Systems make Industry 4.0 possible and the smart factory a reality. As a result of the support of smart machines that keep getting smarter as they get access to more data, our factories will become more efficient and productive and less wasteful. It is the network of these machines that are digitally connected with one another and create and share information that results in the true power of Industry 4.0.”

How it is explained above can certainly be similarly applied in mining as well.

Challenges

Where decarbonisation and digitalisation once presented the mining sector with a steep learning curve, that is not the case anymore. Miners know that data and smart machines can improve safety, help them lower their emissions, and improve their bottom line. There are sometimes internal organisation or cultural hurdles to overcome, however.

There are other challenges too, aside from knowing what to implement, and how. One such challenge is the shortage of people with the right skills to embrace the Mining 4.0 revolution. Academia is needed to support mining companies with research and further educate engineers and future graduates. Digitally literate and dynamically capable mining engineers (with skills such as data management, analytics, digital literacy, and the like) will continue to be in high demand in the coming decades.

Increasing regulatory pressures and rising energy costs are additional challenges miners must navigate on top of the ever-present highly cyclical market conditions and capital-intense operations. Though there is much to navigate, it would be advantageous to manage the many challenges and capitalise on the rising demand for minerals. To do this, companies must innovate and lower their operating costs to remain profitable and viable.

As Smart Miner reports: “While change is always difficult, the promise of technology (and Industry 4.0, Mining 4.0) is a welcome and required one for mining companies. Digital technologies and automation, or Mining 4.0, is defined by smart equipment, drive data-driven (and thus better) decisions, catalyse connected communications and provide easier, more affordable maintenance. From there, mining companies will be able to speed up production, reduce downtime and boost employee safety – three pillars that have challenged mining operations for years.”

Industry 4.0 applications in mining

In the face of mounting ESG, cost and other pressures, big players in the mining industry have been quick to explore ways smart machines can improve their business. Greater reliability and lower costs mean it is starting to make more sense for miners to adopt emerging technologies.

An example Industry 4.0 in action across the mining industry, in utilising big data. Connected machines collect a large volume of data to identify equipment performance, maintenance and identify patterns faster than a human would in a short timeframe. Global consultancy McKinsey & Company mentioned a case study which wowed the industry several years ago as an example. An African gold mine identified a problem with unsuspected fluctuations with oxygen levels during leaching, which is a key process. The mine found a way to capture more data from its sensors resulting in the mine fixing its yield by 3.7 percent (worth up to $20 million annually at the time).

Other ways smart data is helping miners is with:

Coordination

Smart data plays a huge role in the optimisation of logistical coordination and supply chains. When a supply chain is connected, it can adjust or modify mining priorities in times of poor weather, staffing shortages or shipment delays.

Robots

Autonomous and remote-controlled robots have become more affordable and available, meaning they are not just being developed or used by the big miners. In coming decades mining machines and mechanisms are being touted in the industry as becoming “virtually industrial robots”.

Internet of Things

The Internet of Things and the cloud is a key component of Industry 4.0. When devices are connected, including through the cloud environment where data is stored, equipment and operations can be optimised.

The future

Industry 4.0 is still evolving, and while the revolution’s true potential might not be realised for another 20-30 years – mining companies which are constantly assessing and exploring ways to integrate the technologies presently are already reaping the rewards.